Control system



March 8, 1938. a w JONES 2,110,707

CONTROL sqsTEM Filed Oct. s, 1936 Inventor: Benjamin Wdones by dTJwlw bk 0 r-ney.

20' used for rapidly decelerating a motor and its load.

Patented Mar. 8, 1938 PATENT OFFICE v CONTROL SYS'llEM '1 Benjamin W. Jones, Schenectady, N. Y., assignor to General Electric Company, a corporation of New York Application October 8, 1936, Serial N 104,604

7 Claims.

This invention relates to control systems, more particularly to systems for controlling the starting, stopping and running of electric motors, and

it has for an object the provision of a simple,

reliable, inexpensive, and improved system of this character. 7

More specifically, the invention relates to systems forcontrolling the counter current braking of an electric motor. This operation is often referred to as "plugging the motor. The terms counter cur-rent braking and fplugging have the same meaning throughout the specification and claims. A motor is plugged when the armsture is rotating in one direction and voltage is applied which tends to cause the motor armature to rotate in the opposite direction. A direct current motor may be plugged by reversing the voltage on either the field or on the armature. When a motor is plugged, a powerful braking torque is exerted and for this reason plugging is frequently Normally the counter voltage of a motor'opposes-the line voltage, and therefore, limits the motor current to a relatively low value. However, when the motor is plugged, its counter voltage is reversed, andbecomes additive to the line voltage. '11 the motor is plugged when operating at full speed, the resultant voltage, i. e., the sum of theline and counter-voltage, tends to cause an abnormal current to flow which is many times- 7 the normal full load current. Means must be provided for limiting this current to a safe value. The resistor used for starting and accelerating the motor from rest can be reinserted at the instant of plugging to assist in limiting the current and torque to safe values. However, the amount of resistance required for starting and accelerating is usually much less than the amount required to limit the plugging current'to a safe value when the motor is plugged while rotating at a relatively high speed. For that reason an additional section of resistance, usually referred to as the plugging section, is connected in series with the starting resistance, and the total resistance is inserted when the motor is plugged. Since the plugging section of resistance is in addition to the resistance utilized for starting and accelerof the motor to be responsive to the counter voltage. I Such a connection, however, introduces new difliculties, because if the plugging relay is energized by the counter voltage to maintain the plugging section short circuited when starting and during normal running, it will also respond to the counter voltage and short circuit the plugging sections when the motor is plugged "while running ata fairly good speed, and thus the desired protection is not obtained. Accordingly, a

further object of this invention is the provision of a plugging control in which the plugging relay is actuated by the counter voltage of the motor and in which the plugging relay causes the plugging section to be inserted when the motor is plugged and also causes the plugging section to be short circuited when the motor is started from rest and during normal running.

In, carrying the invention into eiiect in one form thereof, an electric motor is connected to a supply source through a current limiting device and an electroresponsive device, connected to be responsive to the counter voltage of the motor, is provided for controlling the current limiting device. Means are provided for establishing counter current braking connections for the motor, and in addition means are provided for preventing the electroresponsive device from responding to the motor counter voltage to insert the current limiting device in the motor circuit during starting and during normal running and for causing the electroresponsive device to respend and insert the current limiting device when the motor is plugged while operating at a speed above a predetermined value.

For a better and more complete understanding of the invention reference should now be had to the following specification and to the accompanying drawing, the single figure of which is a simple, diagrammatical representation of an embodiment of the invention.

Referring now to the drawing, an electric motor I is supplied from a suitable source illustrated in the drawing by the two supply lines II and H to which the motor may be connected by suitable means, such as the electromagnetic contactors l3 and i4. Although the motor l0 may be of any suitable type, it is shown for the purposes of illustration as a series type direct current motor provided with a series field winding i5 and with a series commutating winding l5. When the contactor I3 is operated to its closed position, it connects the motor to the supply source for operation in the forward direction, and when the contactor is closed, the motor is connected to the source -for rotation in the reverse direction.

For the purpose of limiting the motor current to safe values, suitable current limiting means are provided. These means are illustrated as comprising a resistance having a section it connected in the motor circuit for limiting the motor current during the plugging operation and additional portions l1 and is connected in the motor circuit between the plugging section and one side of the line for limiting the motor current during starting and acceleration of the motor. The inclusion of these resistance sections in the motor circuit and the short circuiting of these resistance sections are effected by suitable means such as electromagnetic contactors i9, 30, and 3| for controlling the resistance sections l3, I1, and II respectively. The contactor is which controls the plugging section of the resistance is usually referred to as the plugging contactor, whilst the contactors 20 and II which control the accelerating sections l1 and ll of the resistance are known as accelerating contactors. As shown in the drawing, the plugging contactor I3 is jointly under the control of a reversing multi-podtion master switching device 32 and an electroresponsive device 23 referred to as a plugging relay. It will be noted that one terminal of the winding 33. of the plugging relay is connected to a point between the side if of the source and the main contacts of the reversing contactors i3, i3, whereas the opposite terminal of the winding 23. is connected to a point between the opposite side of the supply source and the main contacts of the reversing contactors i3, H. In other words, the operating coil of the plugging relay is connected outside the main contacts of the reversing contactors so that it is connected across the armature terminals of the motor Ill only so as to be responsive to the counter voltage of the motor I. when one or the other of the reversing contactors is closed.

The plugging relay 33 is so designed and constructed that it will attract its armature when connected across a voltage drop of a predetermined critical value. When thevoltage drop is less than this value, the armature oi the relay is unattracted. As shown, the plugging relay 23 is a normally closed relay, 1. e., its contacts are closed when its coil is deenergized. The contacts of plugging relay 23 are connected in, the energizing circuit of the operating coil of the plugging contactor l3. The energizing circuit of the plugging contactor also passes through the master switch 33 and through the normally open interlock-contacts of the reversing contactors i3 and it. In order to close the plugging contactor II to short circuit the 911188 8 section 13 of the resistance, it is necessary for the master switch .33 to be operated to one of its running positions, for one or the other of the reversing contactors i3, it to be actuated to its closed position, and for the plugging relay'to be deenergized and its contacts in the closed podtion in which they are illustrated. However, when one or the other of the reversing contactors l3 or I3 is closed, the operating coil 33. of the plussins relay is connected across the terminals the motor armature. In order to prevent the plugging relay 23 vice 23 connected in the energizing circuit of the relay 23. Although any suitable type of rectifying device may be-used, preferably an inexpensive plate surface contact type rectifying device, such for example as a copper oxide rectifying device conventionally illustrated in the drawing, is employed. It will be understood however, that any other suitable form of rectifying device may be utilized if desired.

With the foregoing understanding of the elements and their organization in the system, the operation of the system itself will readily be understood from the following description:

With the system in the normally deenergized condition, in which it is illustrated in the drawing, the motor ill is started in the forward direction by operating the master switch 23 to its first operating position for the forward direction of rotation. In this position-of the master switch,

an energizing circuit is established for the operating coil of the forward contactor l3. This circuit is traced from the positive supply line H through conductor 25, fingers 26 and 21 of the master switch, bridged by segment 23, conductor 23, operating coil of contactor- I3 and thence by conductors 33 and H to the lower side I! of the supply source. Simultaneously, the fingers 32 and 33 of the master switch are bridged by the segments 33 and 35 and thus an energizing circuit for the plugging contactor i9 is partially completed through fingers 32 and 33 and through the normally closed contacts of the plugging relay 33. 1 Forward contactor l3 closes in response to energization and connects the armature of the motor II to the source II for rotation in the forward direction. In the closed position of the forward contactor l3, its upper auxiliary interlock contacts complete the energizing circuit for the operating coil of the plugging contactor II which thereupon closes its contacts and short circuits the plugging section ll of the resistance. This sequence of operation takes place so rapidly that the operation of the master switch 33 to a running position and the short circuiting of the plugging sections i3 take place practically simultaneously.

At the instant of the closing of the main contacts of the forward contactor l3, a voltage drop appears across the resistance sections i3, i1, and I3. 'Ihe voltage drop across the plugging section of the resistance I3 is suiiicient to energize the accelerating relay 33 and similarly the voltage drop across the sections I3 and I1 is sufllcient to energize the accelerating relay 31. As a result, both of these relays respond to the voltage drop across the resistance sections and open their contacts.

The short-circuiting of theresistance section It allows suiiicient current to flow in the armature circuit of the motor to cause it to accelerate. As it accelerates. its counter voltage builds up and if it were not for the rectifying device 34 in the energizing circuit of the plugging relay 23, the

latter would respond at a predetermined value of 1s the counter voltage and open its contacts to deenergize the plugging contactor l9 and reinsert the plugging section IS in the motor circuit. However, the rectifying device 24 is so connected that it allows no current to flow through the Operating coil of the relay 23 when the motor is starting from rest and consequently the plugging section I6 is maintained short-circuited during. starting of the motor.

from this point the energizing circuit is traced through the segments 34, 35, and 38, finger conductor an to the open contacts of the accelerating relay 35. The relay 36 was maintained open in response to the voltage drop across the plugging section it. However, short-circulating of this section of the resistance by the plugging contactor i9 caused this voltage drop to disappear and after an interval or" time determined by the constant of the relay 36, the latter closes its contacts to complete an energizing circuit for the accelerating con'tactor 20 through its operating coil and the conductors All and Bi to the lower side l2 of the supply source. sponding to energization closes its contacts to short circuit the accelerating section ll of the resistance and thereby to increase the speed of the motor ill.

The short-circuiting of section ll of the resistance causes the voltage drop across this section to disappear and after an interval of time determined by the constants of the relay 3i, the latter closes its contacts to complete an energizing circuit for the accelerating contactor it through its operating coil and the conductor ii to the lower side of the supply source it. The contactor 2i closes its contacts in response to en- 'ergization and short-circuits the final accelerating section 18 of the resistance and thus completes the acceleration of the motor ill which now rotates at full running speed.

Although the operation of the master switch 22 from its off position to its full running speed position is described as taking place in defiinite steps, it will be understood that the operator usually carries out this operation by throwing the master switch quickly and in one motion from the off position to the full running position.

Now assuming that the motor is operating at full speed and that it is desired to plug the motor quickly to rest, this operation is accomplished by operating the master switch 22 in the reverse direction. The operator usually accomplishes this operation in a single complete movement, quickly throwing the master switch from the full speed forward position to the full speed reverse position. As the master switch is moved from the second forward position to the first forward position, the energizing circuits of the accelerating contactors 2B and ii are interrupted and these contactors open their contacts to insert resistance sections ii and. i3 in themotor circuit. Similarly, as the master switch is moved from its first forward position to its oil position, the energlzing circuit for the plugging contactor i9 is interrupted, as a result of which this contactor opens its contacts and inserts the plugging section I 6 of the resistance in the motor circuit. In like manner, as the master switch 22 is moved Contactor 2c in re-- to its central or off position, the energizing cir-= cuit for the forward contactor is interrupted and this contactor opens its main contacts disconnecting the motor from the supply source and also opens its auxiliary interlock contacts further to interrupt the energizing circuit for the plugging contactor iii.

In the first reverse position of the master switch 22, an energizing circuit is completed for the operating coil of the reverse contactor I4.

This energizing circuit is readily traced from the finger 26 through segment 42 and finger 43, conductor 44, operating coil of reverse contactor i land thence through conductors 30 and 3| to the lower side of the supply source. The contactor it closes in response to energization and connects the motor it to the line for rotation in the reversedirection. It is important to note that contactor iii in closing reverses the connections of the operating coil 23a of the plugging relay 23 to the armature terminals of the motor it. Since at this point in the operation, the retation of the armature is still in the same direction and the current in the main field winding i5 is still in the same direction, the counter voltage of the motor is in the same direction as before. However, since the connections of the energizing circuit of the plugging relay 23 are now reversed with respect to the armature terminals of the motor it. the rectifying device 2Q allows current to flow through the operating coil 23a. of the plugging relay 23. If the motor It) was running at high speed when plugged, as described in the foregoing, the counter voltage of the motor will be sufilcient to energize the relay 23 and to cause it to open its contacts. This interrupts the energizing circuit for the pluggingcontactcr iii and consequently, the plugging contactc-r remains open and the plugging section l6 of the resistance is inserted in the armature circuit and is effective to limit the armature current to a safe value. Similarly, since the energizing circuit of the accelerating contactors 2B and 2i pass through the contacts of the plugging relay 23,

these contactors remain open and the accelerating sections ii and iii are also inserted in the armature circuit to assist the plugging section it in limiting the armature current toa safe value.

It will be understood that when the motor is running at full speedand its armature is suddenly connected to the line for rotation in the reverse direction, its counter voltage, which previously opposed the line voltage now adds to the line voltage and consequently substantially 260% voltage is applied across the resistance in the armature circuit. Obviously, if the plugging section 86 of the resistance were short circuited at this time, the current would rise to a dangerously high value. Even with the plugging section 18 of the resistance in circuit, the current rises to a substantial value and produces a large braking torque, as a result of which the speed of the motor is rapidly decreased. As the speed and counter voltage of the motor are decreased, the energization of the plugging relay 23 decreases in proportion. At a predetermined low value of counter voltage and therefore at a predetermined low speed of the motor Hi, the energization of the relay 23 is decreased sufiiciently to allow the relay to close its contacts and to complete an energizing circuit for the plugging contactor lil. This circuit is traced from the upper side ii of the supply source through the fingers 26 and 43 bridged by the segment 42 of the master switch, conductor 44, upper interlock contacts of reverse contactor I4, normally closed contacts of plugging relay 23, fingers 32 and 33 bridged by segments 45 and 46, operating coil of plugging contactor I9 and thence through conductors 41 and 3| to the lower side I2 of the supply source. Plug- .ging contactor I9 now closes and short circuits the plugging section It of the resistance, substantially at the instant that the speed of the armature of the motor In becomes zero.

Since the armature of the motor I is connected through the reverse contactor I4 to the source, it immediately begins to rotate in the reverse direction. As the direction of rotation of the armature reverses, the polarity of its counter voltage also reverses and the rectifying device 24 in the energizing circuit of the plugging relay 23 again prevents current from flowing in the energizing circuit. Consequently as the motor It comes up tospeed in the reverse direction, the energizing circuit for the plugging contactor is maintained closed and the plugging section I6 of the resistance is short-circuited. From this point, the acceleration of the motor in the reverse direction is substantially identical with the acceleration in the forward direction described in the foregoing.

Thus, it will be noted that when the motor is plugged while running at a fair speed, the rectifier 24 allows current to flow in the energizing circuit of the plugging relay 23 and causes the latter to open its normally closed contacts and interrupt the energizing circuit of the plugging contactor Iii, so that this contactor opens and inserts the plugging section IS in the armature circuit of the motor'and thus provides the required protection during plugging. It will also be noted that when starting from rest and during normal running operation, the rectifier 24 prevents'current from flowing in the operating winding of the plugging relay 23 so that the normally closed contacts of this relay complete an energizing circuit for the plugging contactor I3 and thereby causes this contactor to short circuit the plugging section I6 of the resistance at a time when it is not needed.

A further advantage of the system as described is that when starting from rest the plugging contactor I9 is energized substantially simultaneously with the closing of one or the other of reversing contactors I3, I4 because the contacts of the plugging relay 23 are normally closed. If it were necessary to wait for the plugging relay to close its contacts to complete the energizing circuit for the plugging contactor I9, additional time would be lost. In an application in which the motor may be reversed thousands of times in a day, this additional time lost with each starting of the motor would add up to a very substantial amount when aggregated over a period of months or years. It will thus be seen that the described arrangement decreases the lost time and therefore increases the efliciency of the motor and the apparatus driven thereby.

Although in accordance with the provisions of the patent statutes, this invention is described as embodied in concrete form, it will be understood that the elements and connections shown and described are merely illustrative'and that the invention is not limited thereto since alterations and modifications will readily suggest themselves to persons skilled in the art without departing from the spirit of this invention or from the scope of the annexed claims.

What I claim as new and desire to secure by Letters Patent of the United States, is,

1. A control system comprising in combination an electric motor, a current limiting device in circuit therewith, an electroresponsive device connected to the armature terminals of said motor so as to be responsive substantially solely to the counter voltage of said motor for controlling said current limiting device, means for establishing counter current braking connections for said motor and means'for preventing said electronsponsive device from responding to said counter voltage during normal running operation of said motor, and providing for actuation of said electroresponsive device to render said current limiting device active upon establishment of said braking connections.

2. A control system comprising in combination an electric motor, a current limiting device in circuit with said motor, a relay having an energizing circuit connected to the armature terminals of said motor so as to be responsive only to the counter voltage of said motor for controlling said current limiting device, a rectifier connected in said energizing circuit for maintaining said relay inactive during normal running operation of said motor, and switching means for establishing counter current braking connections for said motor and for reversing the connections of said energizing circuit with respect to the counter voltage of said motor whereby said rectifler passes current and causes said relay to respond and render said current limiting device active.

3. A control system comprising in combination, an electric motor, a current limiting resistance in the armature circuit thereof, a relay for controlling said resistance, said relay having an operating winding connected to the armature terminals of said motor so as to be responsive only to the counter voltage of said motor, a rectifier connected in said circuit for maintaining said relay deenergized during normal running operation of said motor thereby to short circuit said resistance, and switching mechanism for establishing counter current braking connections for saidmotor and for simultaneously reversing the connections of said rectifier with respect to the voltage of said motor, thereby to provide for energization of said relay and short-circuiting said resistance.

4. A control system comprising in combination an electric motor, a current limiting resistor in circuit therewith, a contactor for controlling said resistor, said contactor having an energizing circuit, a relay having an energizing circuit connected to be responsive to the counter voltage of said motor and having normally closed contacts in the energizing circuit of said contactor, and a rectifying device connected in the energizing circuit of said relay to prevent energization of said relay and thereby to effect energization oi said contactor to short circuit said resistor during normal operation of said motor, and for effecting energization of said relay and deenergization of 58141 contactor thereby to remove the short circuit about said resistor in response to establishment of counter current braking connections for said motor.

5. A control system comprising in combination an electric motor, a current limiting resistor in circuit therewith, a contactor for controlling said resistor, said contactor having an energizing circuit, a relay having normally closed contacts for partially completing said energizing circuit, said relay having an energizing circuit connected to be responsive to the counter voltage of said motor, reversing switching mechanism for energizing said motor for operation in a selected direction and for completing said contactor energizing circuit thereby to eiiect short circuiting of said resistor, a rectiiying device connected in said relay energizing circuit for preventing energization' of said relay and interruption of said short circuit when starting saidmotor from rest and during normal running operation and providing iorenergization of said relay thereby to interrupt said short circuit and render said, current limiting resistor eil'ective upon establishment of counter current braking connections for said motor.

6. A control system comprising an electric motor, a current limiting resistor in circuit therewith, a contactor for controlling said resistor, said contactor having an energizing circuit, a relay having normally closed contacts in said energizing circuit, an energizing circuit for said relay, reversing switching mechanism for said motor and for connecting said relay energizing circuit to said motor and completing said contactor energizing circuit to effect short circuiting of said resistor, and a rectifying device in said relay energizing circuit for preventing energization ofsaid relay and interruption 01' said short circuit during'starting and normal running and providing i'or energization of said relay and interruption of said short circuituponoperation of said reversing switching mechanism to establish counter current braking connections for said inotor.

7. A control system comprising in combination, an electric motor, a current limiting re sistor in circuit therewith, a contactor for controlling said resistor, said contactor having an energizing circuit, a relay having normally closed contacts in said energization circuit, an energizing circuit for said relay, reversing switching mechanism for said motor and for connecting said relay energizing circuit to said motor, a

reversing master switch for controlling said reversing switching mechanism, said master switch being provided with contacts for completing said contactor energizing circuit upon operation of said master switch from its of! position to a running position, to effect short-circuiting of said resistance, and a rectifier in said relay energizing circuit for preventing operation of said relay to render said resistor efl'ective during starting and normal running of said motor and providing for energizing said relay to render said resistor ef fective upon operation of said master switch to establish counter current braking connections for said motor.

BENJAMIN W. JONES. 

